150 series

Off-road Karting

USER’S MANUAL

Dear Sir or Madam,

Thank you very much for your choice of KD-150

Off-road Karting.

The KD-150 Off-road Karting, is manufactured

according to the full survey of market demand. We hope

that it will bring you driving pleasure.

Please read the manual carefully before driving

because it will help you learn the basic knowledge of

structure, function, operation and maintenance of the

Karting, which will be of great help for you to keep it in

good condition and drive more safely.

The materials and pictures provided in the Manual

is the latest information made according to the newest

products. There possiblely are differences between the

contents in the manual and the actual situation of

Karting as a result of the improvement or changes of the

products. But the user has to operate by the real

situation. The producer preserves the rights revision of

the Manual at any time, with no further information or

notice.

No one can copy, quote or print any part of the

Manual without permission from the producer.

Please contact the dealers if you have any

problems about the karting’s operation and

maintenance.

▲ Warning: Drivers and Parents should

read and follow the rules in Section 4 before driving Off-road Karting, which is about the important events and safety.

Contents

1. Brief Introduction to Off-road Karting 2. Main Technical Parameter Table 3. Vehicle Assemblage 4. Important Events and Safety 5. Components and Operation Introduction 6. How to Drive Off-road Karting Properly 7. Maintenance of Off-road Karting 8. Schematic Diagram

Attention: the picture shows the external size for the KD-150FS Karting and the size in the bracket is for the KD-150F Karting

1. Brief Introduction to Off-road Karting 1.1 Brief Introduction

1. Beam Light 2. Front Basket 3. Front Guard Pole 4. Control Panel

5. Steer Wheel and Steer Pole 6. Upper Guard Pole 7. Back Gear

Device 8. Hand Brake 9. Driver’s Seat 10. Assistant Driver’s Seat

11. Oil Tank 12. Rear Basket 13. Rear Braking Light 14. Rear

Frame 15. Air Filter 16. Rear Wheel 17. Engine Assembly 18.

Rear Shock Absorber 19. Battery 20. Seat Adjuster

◆ The shape of KD-150 Off-road Karting for leisure

and entertainment is new and unique. The frame is

welded with excellent steel pipe, which is high in

structural strength with reliable safety.

◆ Front independent suspension and articulated

and complicated shock-absorber in the rear frame are

adopted, which is comfortable and is of great help to

prolong the life of the components of the whole vehicle.

◆ Front wheel and rear axle fluid power disk brake

is adopted, which has a good effect and easy and soft

operation.

◆ This type of karts has taken 150 cc engine with

high efficiency and low oil consumption.

◆ The electrical system is simple and reliable as well,

which is a leisure and entertainment vehicle based on

good function.

◆ Stepless speed changing engines are adopted in

the vehicle, better and convenient customer in energy

usage.

1.2 Engine and Frame Identification Numbers Engine Identification Number: Please remember Engine

Identification Number for the check when necessary.

The location of Engine Identification Number is at the

mouth of the discharge pipe of the engine.

Frame Identification Number: Frame Identification

Number is the unique number for all the vehicles and

please make a record for the check when necessary. It is

on the framework under the seat.

2. Main Technical Parameter Table

Item Parameters

Vehicle Type KD-150

150F 150FS

External Dimensi

on

L × W × H

(mm) 2100×1250×1360 2240×1380×1360

Axle Base (mm)

1460 1610

Weight

Dry Weight (Kg)

116 140

Passenger(s) 1 2

Engine

Type Single Cylinder, Four

Strokes, Wind Cooling

Single Cylinder, Four Strokes,

Wind Cooling

Exhaust (ml) 150 150

Form of Speed Changing

stepless speed changing (with back

gear)

stepless speed changing (with back

gear)

Power Highest Speed (km/h)

70 65

Package Size

L × W × H

(mm) 2110×1300×860 2260×1430×860

Transport

Size and Number of Container

40′H / 27 40′H / 24

Tire

Type/Air Pressure Front

19×7-8 10 P.S.I 19×7-8 10 P.S.I

Type/Air Pressure Rear

18×9.5-8 15 P.S.I 22×10-10 15P.S.I

Electrical System

Battery 12V 9Ah

Safety Fuse 10A

Power Highest Speed (km/h)

5.0

3. Vehicle Assemblage

1. Take off the front and rear fixing poles by using

wrench.

2. Take out Steer Wheel and 6 pan head cruciform

slot screws (M6×12) from the plastic bags and install

Steer Wheel on the Steer Wheel fixing base (pay

attention to the place of Steer Wheel, put the front

turning wheels parallel to the rear wheels, let Steer

Wheel with 3 strips up face the rear). Fasten the screw

and put on the cover of Steer Wheel.

3. Put the protective small plastic jacket into the

pipe (diameter: φ25) of goods shelf, put the screw bolt

backings into the hexangular flange face screws (M8×

60) and then fix the goods shelf with the backing screw.

4. Put the protective large plastic jacket into the pipe

(diameter: φ32) of goods shelf, put the screw bolt

backings into the hexangular flange face screws (M8×

60) and then fix the protective pipes with the backing

screw.

5. Take the oil tank from the box and fix on the oil

output mouth. Fix Oil Tank on the supporter by 4

hexangular flange face screws (M8×25). Put one end of

non-burning rubber oil-input pipe into the oil-output

mouth. Take off the dust-free cover on the mouth of the

Carburetor, put the other end to the input oil mouth on

the Carburetor.

6. Take out the hexangular screws (M8×40) and

non-metal hexangular locker screw nuts from the bag

and fix the seat.

7. Loosen the screw nuts and plugs on the wire

poles and connect the negative pole to the same place

of the battery (attention: the negative pole connect to the

positive pole of the battery, black wire connects to the

negative pole of the battery). Tighten the screws.

8. Plug in the joints of the rear lights (2.8 series, 3

holes).

Check and make sure that every screws are tight

and then you can use the kart.

4. Important Events and Safety

KD―150 Off-road Karting is more than a toy and it

will cause danger if driving improperly. Please abide by

the following suggestions strictly to avoid the injury.

◆ You mustn’t drive at an excessive speed. You

must control the speed properly according to the road

situation, the field of vision, your driving experiences and

your operating conditions.

◆ You must drive with defined number of

passengers and loading capacity, with no over-loading

driving.

◆ Keep a proper gap with the other vehicles to

avoid collision.

◆ Please examine the off-road karting before

driving, making sure that it is in the condition that safe

driving can be obtained. You can inspect according to

the process and maintenance specified in the Manual

and the explanation attached to the components,

making sure that all the joints are tightened and safe.

◆ Before starting the engine, you must make sure

that the driver is on the seat and the vehicle is in the

controllable state.

◆ The vehicle is designed to carry one person,

please don’t pick up other passengers.

◆ You must put your hands on Steer Wheel all the

time when driving and make sure that the running

direction is under your control.

◆ The kart should not be overloaded with

passengers.

◆ You must abide by the operating procedures

and methods when turning the vehicle.

◆ You must practice the low-speed turning before

you conduct the high-speed operation. Please don’t turn

at an excessive speed.

◆ You must do warming-up exercises before

driving the vehicle.

◆ Please read the Manual and all the warning

notes carefully before driving and operate by following

strictly the procedures and methods.

◆ You mustn’t drive the vehicle on the street,

driveway or sidewalk.

◆ You mustn’t drive off-road karting under the

influence of drink or anesthesia agents because this will

badly reduce you judging ability and cause serious injury

and even death.

◆ You must drive on the slippery and steep road

after mastering the skills of driving for it is dangerous to

do so. Attention: driving on the slippery, broken stone or

soft road will prolong the braking distance.

◆ You must drive on the strange road slowly and

carefully.

◆ You must learn how to drive off-road karting in a

proper way and a qualified training coach is a necessity.

The driver must be more than 16 years old and of

adequate understanding, intelligence and judging ability

for controlling the driving safely.

◆ You must add petrol to the oil tank before you

drive it for the first time. If it is two-stroke engine, you

must add the petrol with proper quantity of engine oil

and the ratio of petrol and engine oil is 25:1. If it is

four-stroke engine, you must add the engine oil in time

according to the requirement of the engine. Attention:

please don’t add the fuel when the engine is in operation

or it is hot. You must keep the source of heat and the

flame away from the oil tank.

◆ You must adopt the tires of size and type

defined in the Manual and keep the tire at the defined air

pressure. The proper air pressure can ensure the

reliable braking and turning.

◆ Please don’t change the position and the state

of the components or add any attachments at your will.

◆ You mustn’t operate the engine in a closed

environment because CO2 from it will be dangerous to

life.

◆ It is dangerous for any parts of body or clothes

to touch the engine, noise deadener or any other

revolving parts. Please keep away from them.

◆ You must follow the local suggestions and rules

to drive the mini off-road karting in helmet and protection

clothes.

◆ You must fasten the seat belt when driving, with

no hand, foot or head exposing outside of the vehicle.

◆ You must follow the rules and the regulations of

the sports ground or the local authorities when driving

for pleasure.

◆ Please don’t drive the vehicle if your body

dimension or health status are not suitable.

◆ Please keep the vehicle far away from the

resource of heat and fire if you store it for a short time.

Please empty the petrol in the oil tank if you store it for a

long time. Please store the Manual properly for the

necessary usage.

◆ Certain experiences are required to repair and

maintenance the vehicle and all the actions of its kind

must be done under the safe conditions.

5. Components and Operation Introduction

5.1 Location of Components

See Picture 1.1

5.2 Operation of Components

☆ Steer Wheel

Steer Wheel is used to control the direction of the

off-road karting and the kart will turn right or left

according to the corresponding operation.

☆ Braking Pedal

Braking Pedal is operated by left foot. It will work

when step hard forward and the off-road kart will slow

down.

▲ Warning: You must keep the hands on Steer

Wheel to avoid the losing control of the kart when driving the off-road karting. Otherwise it may cause serious accidents even death.

▲ Warning: You must be skillful in the operation

and the force Braking Pedal and Gas Pedal when driving initially Off-road Karting so that you can control the speed properly especially in the curves and among the karts.

☆ Gas Pedal

Gas Pedal is operated by right foot. It will accelerate

when step hard forward and slow down otherwise.

Braking Pedal Accelerating Pedal

☆ Gear-engaging Device

Gear-engaging Device Forward Gear

Backward Gear

If there is gear-engaging device in your karting, you must make clear the function and operating ways of each gear so that you can avoid the danger arising from the unexpected running.

The back gear device for KD-150F is located at framework of right of the seat and the back gear device for KD-150FS is located at the right and lower part of Steer Wheel.

The gear-operating ways for the engine are as follows:

Move the handle backward and locate the gear pole at the back gear, the kart will go backward.

▲Warning：

Attention：you must stop when conduct gear changes.

Control Panel (Ignition Key and Blanket Switch)

Ignition Key Blanket Switch Horn Switch

☆ Ignition Key

Turn the Ignition Key clockwise to the first gear and

Braking Indicator will be on.

Engine-start 1:Electric Start (Ignition Key is on

Control Panel)，you can start the engine by turning

Ignition Key clockwise to the second gear.

Engine-start 2: Turn the Ignition Key clockwise to the first gear and trample down for several times the footpedal, which is in the left of the engine, until the engine starts.

☆ Blanket Switch

If you want to stop the engine, you can press the

red Blanket Switch until it stops.

☆ Horn Switch

The horn will be switched on if pressed and off if

loosened.

☆ Seat

You can adjust the location of Seat by moving the

hand lever under the cushion. You can move the hand

lever right, and then move to the place necessary and

loosen the hand lever. Attention: please resume the

location of the hand lever.

Seat Adjuster (back and forth)

☆ Oil Tank (Cover)

There is a blowhole on Oil Tank Cover, which should not be blocked.

The capacity of Oil Tank is 5.0 L. Please don’t add the petrol no more than the neck bottom of oil feeding mouth when adding.

You must fasten Oil Tank Cover after finishing adding petrol.

☆ Hand Brake

The hand brake of KD150F is located at the back of the back gear (KD150FS is between the two seats). The karting will be braked if you pull upward the hand brake when stopped and will be loosened if you put down the brake.

6. How to Drive Mini Off-road Karting Properly

6.1 Preparations before Driving Such preparations are necessary as receiving the proper training and guidance, checking your off-road karting and making sure that it is in good condition and learning the rules of driving safely. You must put on the protecting equipment, such as helmet and long-sleeve clothes. 6.2 Vehicle Check before Driving It is necessary for you to spend few minutes on checking your off-road karting before driving so that you can save time and keep safe in the long-way driving. This include the following items: a. Adding of engine oil

If you use it for the first time, you must add petrol and

engine oil in it.

You must add oil to the engine in time according to the using requirement and the engine oil number is:

*Crank case: SAE15W/40SE , 0.9L; *Gear case: Summer 150-SY1172-80, 0.11L; Winter 10-Q/SY11520-79,0.11L,

b. Quantity of Petrol You must add petrol in time if the quantity of petrol is

not adequate so that it will not break down on the way. You should check the leakage of Oil Tank. The petrol number is above 90.

c. Brake Please check the operation of the brake and adjust

the free path when necessary. d. Tires You should check the tightness of the screw bolt

and screw nut, the state and the air pressure of the tires to see if it is suitable to drive

e. Accelerator Please check the accelerator if it can move freely

and if it can resume its position. f. Ignition Key and Blanket Switch Please check the joints and plugs if they are tight

and work properly. g. Screw Bolt, Screw Nut, Fastener

Please check the wheel axles to see if the screw bolts are

tight and to see if the other screw bolts and screw nuts are

▲ Special Attention: 1. The petrol in the oil tank and the engine oil in the

engine have been emptied for the safe transportation. Before starting, please add petrol and engine oil to the defined place. The petrol number is 90 or above and the engine oil number is 85w/90.

2. The karting has gear system and you must put the gear into neutral till the indicator is on (the gear indicator is in front of the frame) before starting the engine and then run the karting with the necessary gear.

▲ Warning: Attention: Please don’t add petrol or engine oil when the engine is running and keep the oil tank away from the heat resources and flame.

tight and reliable. You must make sure that the screw bolts of

Steer Wheel is tight and reliable and the front wheels turn in

the same direction of Steer Wheel freely.

h. The Lower Part of Vehicle and Exhaust System

Please check and clear the dust, plants and the

other foreign substances that will possibly cause fire or

wrong operation.

You must clear all the faults before driving and you

can also ask help from the dealer of franchiser if you fail

to do so.

6.3 Steps of Start the Engine

☆ Put the vehicle on the flat place.

☆ Put Ignition Key to the location of starting the

engine, with no more than 10 seconds every time. Please press slightly Gas Pedal and repeat the above-mentioned steps if you fail to start it for several times. 6.4 Running-in Please don’t run at a too fast speed or even tread Gas Pedal to the bottom in the first few weeks driving the new vehicle. The right way to run in the engine will be of great help for the life and performance. It will be better to run in the engine at a various revolving speed.

6.5 Driving You should choose a safe and flat place without any obstacles and vehicles to conduct the initial driving. After starting the engine and allowing running for a moment for warming-up, you can drive by grasping Steer Wheel, seeing the front ways and treading Gas Pedal gradually. 6.6 Turning You should control the speed properly when turning and it will be difficult to run in the expected direction and track if you run at an excessive speed. You should use Gas Pedal and Braking Pedal properly to ensure the security when turning. And you should lurch to the turning direction. 6.7 Stop It will be better for you to choose a flat place to park the vehicle. When parking, you should loosen Gas Pedal and tread Braking Pedal, reducing the speed until it stops. After parking the Karting, you can loosen the brake pedal only after pull up the hand brake so that you can avoid the automatic moving.

▲ Warning: It will increase the possibility of the

accidents if you don’t check the vehicle and clear the faults before driving. You should check it according to the procedures and maintenance in the Manual and make sure that the vehicle is in good and safe condition.

▲ Attention: You should practice the turning at a

low speed firstly and increase the speed gradually to get familiar with the operating features of the off-road Karting.

7. Maintenance of Mini Off-road Karting 7.1 Routine Maintenance The following is the routine maintenance table. It is make according to the general situation and you must conduct the maintenance more frequently if the driving environment is worse and dust is more.

Routine Maintenance Table

Notes: I-Inspection, clean, adjust and lubricate when necessary, C-Clean, R-Replace, L-Lubricate

Item Maintenance in 1st Week

Monthly Maintenance

Annual Maintenance

Petrol Pipe Line

System* I I

Accelerator* I I

Air Filter C

Sparkling Plug

I

Engine Idle Speed

I I

Drive Chains

I, L I, L

Braking Disk Fretting quantisty

I

Braking System*

I I

Screw Bolt, Screw Nut, Fastener

I I

Tires I I

Turning System

I

Front Suspension

System I

Engine Oil*

R

▲ Warning: You should cut off the engine when

conducting maintenance and otherwise it will possibly damage the moving and hot parts.

▲ Warning:

1. When conducting maintenance, please read the operation guidance and warning signs and prepare the necessary tools and auxiliary materials.

2. The clean, flat, ventilating and bright place should be chosen to conduct the maintenance. The engine should be stopped unless necessary. Please choose the real products if it is necessary to change the components.

3. Please ask help from dealers of the producer if you can not conduct the maintenance by yourself.

4. It will be better for you to ask the dealers of the producer to repair or maintenance the items with “*”, unless you have enough tools, maintenance parameters and experiences.

7.3 Sparking Plug

☆ Take off the cap of Sparkling Plug.

☆ Dust the tray of Sparkling Plug.

☆ Take out Sparkling Plug by wrench.

☆ Inspect the electrode and replace it if the

electrode and the nonconductor are burnt in a improper

way.

☆ A new one should be installed if Sparkling Plug

is apparently burnt or the nonconductor is broken.

☆ Inspect the distance between the electrodes.

The normal distance is 0.61-0.71 mm. You must make it

to the right place carefully if the distance is not proper.

☆ Please drive the screw by hand if installing

Sparkling Plug to avoid sliding-filament.

☆ After the above-mentioned step, you can drive

fasten it 1/2 circle (for new Sparkling Plug) or 1/4 – 1/8

circle (for used Sparkling Plug) by the special wrench for

Sparkling Plug.

7.4 Air Cleaner

Routine cleaning is necessary because dust will be

left in Air Cleaner during the use. Frequent cleaning

should be conducted if driving in the dusty area.

7.4.1 Cleaning of Air Cleaner

☆ Take off the plastic protecting jacket.

☆ Take off the cover of Air Cleaner.

☆ Take the filter out of the of Air Cleaner.

☆ You can clean the cleaner in the dissolvent of

inflammable and high flash point. Then soak the filter in

the clean engine oil for 5 minutes and squeeze out the

rest engine oil.

☆ Dust the empty Air Filter Box, the cover and the

entrance and place the dry filter into Air Filter Box.

7.5 Brake Staff

Disk Brake is adopted in the vehicle and you should

inspect the free path of Brake Pedal, the joints of the

braking system and the leakage.

Routine inspection is necessary for the braking disks

to make sure that it doesn’t reach the extreme points.

☆ Free Path of Brake Pedal

▲ Attention: You should tighten Sparkling Plug

and otherwise it will cause the damage of engine as a result of overheating.

▲ Attention: You should not tighten it to squeeze out

the rest engine oil and the otherwise will damage the filter.

The distance between the initial position of the pedal

and working position means Free Path of Brake Pedal.

☆ It is necessary for you to replace the braking disk if

it is less than 2 mm thick.

☆ Please replace the braking pedal if it is not active.

Please pay attention to spring, screw bolt, linchpin and

the pipe when replacing.

7.6 Accelerator

☆ The Free Path of Accelerator is 3– 5 mm, which

can be measured from the initial position to the position

where the revolution begins to rise.

☆ It is necessary to adjust Accelerator Cable and the

screw nut in the end of Carburetor if Free Path of

Accelerator is not in its proper distance. You should lock

it after adjustment.

☆ Please replace Accelerator Cable if it is damaged.

☆ Inspect the return spring of Accelerator Pole and

replace if it can not work properly.

7.7 Tire Check

☆ The tires of the vehicle are low pressure ones, the

proper pressure should be:

KD-150F:

Front Wheels: 19×7-8 Air Pressure 10 P.S.I;

Rear Wheels: 18×9.5-8 Air Pressure 15 P.S.I.

KD-150FS:

Front Wheels: 19×7-8 Air Pressure 10 P.S.I

Rear Wheels: 22×10-10 Air Pressure 15 P.S.I

The over-high or over-low Air Pressure benefits

nothing to the proper performance. The measure of Air

Pressure should be conducted under the cool state.

☆ Depth of Tire Checker

Please check surface and side and make sure that

there is no crack on it, no foreign substances in it and no

leakage of air. You should replace the tire if the depth of

tire checker is less than 2 mm.

7.8 Battery

☆ You must connect the red wire to “+” pole and the

black wire to “-” pole when installing the battery. You

should replace the battery if it cannot store electricity.

Generally speaking, battery should be replaced every

2-3 years.

☆ Safety Wire

Safety Fuse must be installed in the safety wire box.

The size of the safety wire is 10 A.

If safety wire is frequently damaged, there is possibly

a short circuit or over-loading.

The change of Safety Wire:

a. Open safety wire box and take out the safety wire

plate.

b. Insert the new safety wire plate into safety wire box.

c. Resume the cover of safety wire box.

7.9 Carburetor

The idle speed adjusting screw bolt on Carburetor is

used to adjust the speed of idle speed. Tighten the

screw and the speed will slow down; loosen the screw

and the speed will speed up. You must adjust the speed

to the lowest stable position when adjusting.

The rest inspections of Carburetor need certain

experiences and please contact the dealers of franchiser

for technicians’ help.

7.10 Steering System

Routine screw inspections for the Steering Pole,

Steering Machine and Turning Pole are necessary.

Front Wheels: You adjust them by Turning Pole and

the distance is 0 – 3 mm.

KD-150

Off-road Karting

USER’S MANUAL

注：本图所表示的是 KD-150FS 型 Go-kart 外型尺寸，括号内尺寸为 KD-150F 型 Go-kart 尺寸 Attention: the picture shows the external size for the KD-150FS Karting and the size in the bracket is for the KD-150F Karting

1. Beam Light 2. Front Basket 3. Front Guard Pole

4. Control Panel 5. Steer Wheel and Steer Pole 6. Upper Guard Pole 7. Back Gear Device 8. Hand Brake 9. Driver’s Seat 10. Assistant Driver’s Seat 11. Oil Tank 12. Rear Basket 13. Rear Braking Light 14. Rear Frame 15. Air Filter 16. Rear Wheel 17. Engine Assembly 18. Rear Shock Absorber 19. Battery 20. Seat Adjuster

刹车踏板 Braking Pedal 油门踏板 Accelerating Pedal

挂档机构 Gear-engaging Device 前进档 Forward Gear 倒档 Backward Gear 启动按纽 Ignition Key 熄火开关 Blanket Switch 喇叭按纽 Horn Switch

座椅前后位置调节机构 Seat Adjuster (back and forth)